3KW Car Mounted DC-DC Module | High-Power DC/DC Converter for New Energy Vehicles | HLF3000-D27
HLF3000-D27-E | 3kW Automotive-Grade DC-DC Converter Module (Enclosed Version)
High Efficiency · High Reliability · Intelligent · IP67 · Automotive Grade
Overview
HLF3000-D27-E is a fully enclosed, IP67‑rated 3kW automotive‑grade DC‑DC converter module engineered for high‑voltage to low‑voltage power conversion in electric vehicles (EVs), hybrid electric vehicles (HEVs), and commercial electric fleets. Accepting a wide 200–950 VDC input and delivering a regulated 27.5 VDC output (with 13.8V, 48V, and 72V variants available), it achieves ≥94% full‑load efficiency across the entire operating range.
Housed in a rugged aluminum alloy enclosure with integrated cooling fins, IP67 protection, and EMI shielding, this module is designed for exposed, harsh environments such as under‑body, roof‑mounted, or exterior installations. It meets rigorous automotive standards including ISO 16750‑3/‑4 (environmental reliability) and ISO 26262 (functional safety), with an architecture designed to support ASIL‑D level safety goals (certification support available upon request). An eleven‑layer hardware and software protection suite, CAN 2.0B communication, and pre‑installed mounting brackets make it the ideal auxiliary power module for next‑generation electric vehicles, refrigerated transport, and industrial systems requiring robust, efficient, and compact DC‑DC conversion.
Key Highlights
| Feature | Description |
|---|---|
| Ultra‑High Efficiency | ≥94% full‑load efficiency minimizes energy loss. |
| Wide Input Voltage Range | 200–950 VDC input accommodates 400V, 600V, and 800V battery systems. |
| IP67 Ingress Protection | Dust‑tight and waterproof for under‑body, roof‑mounted, and exterior installations. |
| Eleven‑Layer Protection Suite | Reverse polarity, input/output OVP/UVP, OCP, SCP, two‑stage OTP with intelligent derating, inrush limiting, self‑recovery fuse, and fault diagnostics. |
| Automotive‑Grade Reliability | Designed and verified to meet ISO 16750‑3/‑4, ISO 26262 (ASIL‑D ready), CISPR 25 (Class 3), and E‑mark compliance. MTBF > 100,000 hours. |
| Integrated Cooling & EMI Shielding | Aluminum enclosure with cooling fins for passive and forced‑air heat dissipation, plus built‑in EMI shielding. |
Physical Features
Robust Aluminum Alloy Enclosure – Integrated cooling fins for enhanced heat dissipation.
IP67 Ingress Protection – Dust‑tight and waterproof for harsh outdoor and under‑body applications.
Pre‑installed Mounting Brackets – Enables quick mechanical integration with standard automotive mounting points.
EMI Shielding – Reduces electromagnetic interference to comply with CISPR 25 and ensure system‑level compatibility.
IP67‑Sealed Automotive Connector – Supplied with matching connector for reliable, vibration‑proof connections.
Technical Specifications
| Parameter | Specification |
|---|---|
| Model | HLF3000-D27‑E |
| Input Voltage Range | 200 – 950 VDC |
| Output Voltage | 27.5 VDC (13.8V / 48V / 72V optional) |
| Output Power | 3,000 W continuous |
| Output Current | 109 A @ 27.5V |
| Full‑Load Efficiency | ≥ 94% (see efficiency curve below) |
| Output Ripple & Noise | < 100 mVpp @ full load, 20MHz BW |
| Isolation Voltage | 3000 VAC (input to output, reinforced insulation) |
| Enable Control | Active high, 9 -32 V logic compatible |
| Communication | CAN 2.0B (isolated) |
| Cooling Method | Forced air cooling via integrated heatsink (passive cooling also supported in lower power conditions) |
| Operating Temperature | -40°C to +85°C (ambient) |
| Ingress Protection | IP67 |
| Vibration & Shock | ISO 16750‑3 (random vibration) compliant |
| EMC Compliance | CISPR 25 (Class 3), ISO 7637‑2 |
| Functional Safety | ISO 26262 ASIL‑D ready architecture |
| Dimensions (L × W × H) | 263.5 × 201 × 110 mm (±0.5 mm for L and W, ±0.3 mm for internal features) |
| Weight | ~5.0 kg |
| MTBF | > 100,000 hours (Telcordia SR‑332, 40°C) |
| Startup Time | < 500 ms (from input power‑on to output regulation) |
Efficiency vs. Load Curve (Typical)
| Load | Efficiency (@400V Input) | Efficiency (@800V Input) |
|---|---|---|
| 25% | 91.5% | 92.0% |
| 50% | 93.5% | 94.0% |
| 75% | 94.0% | 94.5% |
| 100% | 93.5% | 94.0% |
Protection & Safety Features
HLF3000-D27‑E incorporates a comprehensive, multi‑layer protection system to ensure safe and reliable operation under all conditions. All protection mechanisms are monitored in real‑time via the CAN interface, with fault status and diagnostic data available for system‑level integration.
| Protection Type | Trigger Threshold | Action / Response | Recovery Mechanism |
|---|---|---|---|
| Input Reverse Polarity | ≤ –1000 VDC (1 min withstand) | Series MOSFET disconnects input; no output | Auto‑recovery upon correct polarity |
| Input Over‑Voltage (OVP) | > 975 VDC (typ) | Shutdown (latch‑off); output disabled | Manual reset / power‑cycle |
| Input Under‑Voltage (UVLO) | < 200 VDC (typ) | Prevents startup; stops output if running | Auto‑restart when input > 190 VDC |
| Output Over‑Voltage (OVP) | > 28.5 VDC (clamp) | Output clamped at 30V; latch‑off if exceeded | Manual reset / power‑cycle |
| Output Under‑Voltage (UVP) | < 22 VDC | Hiccup mode (intermittent output attempts) | Auto‑restart when fault removed |
| Over‑Current Protection (OCP) | > 115 A (115% of nominal) | Constant‑current limit → Foldback after 5s | Auto‑restart when load reduced |
| Short‑Circuit Protection (SCP) | Output resistance < 0.5 Ω | Hiccup mode (1Hz retry cycle) | Auto‑recovery when short removed |
| Over‑Temperature Stage 1 (Derating) | Heatsink > 75°C | Linear power reduction: 100% @ 85°C → 50% @ 95°C | Auto‑restore when temp < 80°C |
| Over‑Temperature Stage 2 (Shutdown) | Heatsink > 85°C | Immediate output shutdown | Auto‑restart when temp < 80°C |
| Inrush Current Limiting | Peak inrush < 10A (nominal input) | Active soft‑start; output ramps to full in < 200ms | Internal auto‑complete (no recovery needed) |
| Self‑Recovery Fuse | Internal over‑current / severe fault | PTC fuse disconnects input; output off | Auto‑recovery when fault removed and fuse cools |
Status Indicators & Diagnostics
| Function | Description |
|---|---|
| PWR LED (Green) | Illuminates when input voltage is present and converter is ready. |
| FLT LED (Red) | Illuminates when any protection event is active (OVP, UVP, OCP, OTP, etc.). |
| CAN Fault Reporting | Real‑time fault codes transmitted via CAN 2.0B, including: • Voltage/current/temperature telemetry • Event‑timestamped fault logs (up to 100 entries) • Pre‑failure warning for predictive maintenance (OCP approaching threshold, OTP derating active, etc.) |
| Enable Pin (EN) | Active high (9V-32V logic): Enable → converter ON. Pull low or leave floating: converter OFF (standby, < 1W). |
Mechanical Dimensions
Overall Dimensions: 263.5 mm (L) × 201 mm (W) × 110 mm (H) – tolerances: ±0.5 mm for length and width, ±0.3 mm for internal features.
Mounting: 4 × M4 threaded inserts on the base, pitch 190 × 188.5 mm.
Side clearances: 29.5 mm margins each side for bracket mounting hardware.
Applications
| Industry | Specific Use Case |
|---|---|
| Electric & Hybrid Vehicles | Auxiliary power for HVAC, lighting, power steering, and battery management systems |
| Commercial Vehicles | Electric buses, delivery trucks, and heavy‑duty fleet power distribution |
| Refrigerated Transport | Power supply for temperature‑controlled logistics and cold‑chain systems |
| Telecom Infrastructure | Backup and auxiliary power for 4G/5G base stations (48V variant) |
| Aerospace & UAV | Tethered drone onboard power systems |
| Industrial Power | Auxiliary supplies for heavy equipment, robotics, and automated manufacturing systems |
Why Choose the HLF3000-D27‑E?
✅ Decades‑Proven DC‑DC Expertise
Leveraging over 20 years of power electronics design and manufacturing experience, validated to automotive environmental stress profiles including thermal cycling, humidity, and vibration.
✅ True Automotive‑Grade Certification
Designed and verified to meet ISO 16750‑3/‑4, ISO 26262 (ASIL‑D ready), CISPR 25 (Class 3), and E‑mark compliance – delivering confidence for road‑worthy, safety‑critical applications.
✅ Eleven Layers of Protection – No Compromise
From reverse polarity to intelligent thermal derating, every fault condition is anticipated and managed, ensuring system safety and uptime even under extreme conditions.
✅ Rugged IP67 Enclosure
Protects against dust, water, and vibration, ideal for under‑body and exterior mounting in harsh environments.
✅ Intelligent Control & Real‑Time Monitoring
Built‑in isolated CAN 2.0B interface enables remote voltage/current/temperature monitoring, fault diagnosis, and firmware updates, simplifying integration with vehicle control units (VCUs) and fleet management systems.
✅ Comprehensive Design‑In Support
Access to detailed application notes, thermal simulation models, CAD files, and dedicated engineering support to accelerate your product development cycle.
Frequently Asked Questions (FAQ)
Q: Does this converter include reverse polarity protection?
A: Yes. The HLF3000-D27‑E features input reverse polarity protection via a series MOSFET that disconnects the input when polarity is reversed. The converter automatically recovers when polarity is corrected.
Q: What happens if the input voltage exceeds 950 VDC?
A: The converter is protected by input over‑voltage protection (OVP). If the input exceeds 975 VDC (typical), the converter will latch off and require a manual reset or power‑cycle to resume operation.
Q: How does the thermal protection work?
A: The converter employs a two‑stage thermal protection: Stage 1 starts power derating at 85°C heatsink temperature (linear reduction to 50% at 95°C); Stage 2 shuts down completely at 100°C and auto‑restarts when the heatsink cools to 80°C.
Q: Is the IP67 rating sufficient for under‑body mounting?
A: Yes, IP67 provides dust‑tightness and protection against water immersion up to 1 meter for 30 minutes, making it suitable for under‑body, roof‑mounted, and other exposed locations.
Q: Does this converter support regenerative braking or bidirectional power flow?
A: The HLF3000-D27‑E is a unidirectional DC‑DC converter (HV to LV). For bidirectional applications, please refer to our BDC series (contact sales for details).
Q: Can I configure the output voltage to a non‑standard value?
A: Yes, output voltages of 13.8V, 48V, and 72V are available as standard options. Custom output voltages between 12V and 72V can be supported with minimum order quantities – please contact our engineering team.
Q: Is this converter compatible with 800V battery architectures?
A: Yes, the 200‑950VDC input range supports 400V, 600V, and 800V nominal battery systems, making it future‑proof for next‑generation EVs.
Q: How is the fault status communicated to the vehicle control unit?
A: All protection events (OVP, UVP, OCP, OTP, etc.) are reported in real‑time via the CAN 2.0B interface, with detailed fault codes and timestamped logs.
Q: What is the typical startup time?
A: From input power‑on to output regulation, the converter typically starts in < 500 ms.
Q: Are there any minimum load requirements?
A: The converter is fully regulated from 0% to 100% load and can operate reliably at no‑load conditions.
Q: What is the isolation voltage between input and output?
A: The converter provides reinforced insulation with a test voltage of 3000 VAC (input to output).
Q: What are the EMC compliance levels?
A: The converter is compliant with CISPR 25 Class 3 and ISO 7637‑2 Pulse 1, 2a, 3a, 3b for automotive EMI/EMC requirements.
Ordering Information
HLF3000-D27-E IP67
Custom output voltages (12–72 VDC) and extended temperature range options available upon request with minimum order quantities.
Contact Us
For pricing, detailed datasheets, thermal simulation models, custom configurations, or application‑specific engineering support:
📧 Email:sales@levanepower.com
🌐 Website:www.levanepower.com
📞 Phone: +86‑755‑1234‑5678 (China) / +1‑800‑XXX‑XXXX (North America)
Levane Power – Powering Innovation with Reliability.
